Efficient food packaging

ABSTRACT

One disclosed aspect of the embodiments is a technique to package a dish having strips of dough, garnishes, pieces of meat, and broth. A main container has an inner wall and is configured to be sealed with a main lid. A secondary container has an outer wall and is configured to contain a first type of broth and sealed with a secondary lid. The secondary container is placed inside the main container such that the outer wall and the inner wall form a space accommodating the strips of dough and the pieces of meat. A separator is placed above the secondary container to hold the garnishes underneath the main lid.

TECHNICAL FIELD

The presently disclosed embodiments are directed to the field of food packaging, and more specifically, to take-out food packaging.

BACKGROUND

Food packaging has been important in the food industry. A food package typically serves several objectives. First, it provides a clean, safe, and efficient way to contain the food and protect it from physical damages or degradable effects such as those caused by undesirable temperature, oxygen, water vapor, etc. Second, it serves as a marketing tool to encourage potential buyers to purchase the product. In a grocery store, consumers are likely to pick out an item on the display shelf if the packaging is appealing to them. For take-out or to-go food, the package may also have to be safe and easy-to-handle to provide convenience to consumers. Several packaging types are available on the market such as boxes, cans, cartons, bags, plastic containers, foam cups, biodegradable containers, and paper containers.

While many of the above package types adequately serve their objectives, none of them is suitable for specialty food of which the different ingredients are only mixed at consumption and not possibly during transportation, especially for take-out or to-go food. One type of this specialty food is Vietnamese food. Vietnamese food is famous for the use of a variety of ingredients, spices, herbs, vegetables that add to the five fundamental taste elements (spicy, sour, bitter, salty, and sweet) over the basic ingredients of starch or dough and protein. One particular type of Vietnamese food involves noodles, rice vermicelli, or cellophane noodles served with meat in a bath of broth or sauce and complemented with vegetables or herbs. A fully complemented dish of such type would contain several components including (1) a first solid type: represented by the starch/dough or the various types of noodles or vermicelli, etc., (2) a second solid type: represented by the protein that includes meat or mix of various type of meats, (3) Liquid types: broth and/or sauce, and (4) Garnishes: vegetables and/or herbs. While these dishes may be served quite well in restaurants in bowls for instant consumption, packaging them for take-out or to-go requires proper separation and preservation of the components and therefore is a challenge.

SUMMARY

One disclosed feature of the embodiments is a technique to package a dish having strips of dough, garnishes, pieces of meat, and broth. A main container has an inner wall and is configured to be sealed with a main lid. A secondary container has an outer wall and is configured to contain a first type of broth and sealed with a secondary lid. The secondary container is placed inside the main container such that the outer wall and the inner wall form a space accommodating the strips of dough and the pieces of meat. A separator is placed above the secondary container to hold the garnishes underneath the main lid.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments may best be understood by referring to the following description and accompanying drawings that are used to illustrate embodiments. In the drawings:

FIG. 1A is a diagram illustrating a package assembly, in three-dimensional view, having one inside container according to one embodiment.

FIG. 1B is a diagram illustrating a package assembly, in side view, having one inside container according to one embodiment.

FIG. 2A is a diagram illustrating a package assembly having two inside containers stacked on each other according to one embodiment.

FIG. 2B is a diagram illustrating a package assembly having two inside containers separated by a separator according to one embodiment.

FIG. 3A is a diagram illustrating a package assembly having two inside guides according to one embodiment.

FIG. 3B is a diagram illustrating a top view of a package assembly compartmentalized in the surface dimensions by square or rectangular containers according to one embodiment.

FIG. 3C is a diagram illustrating a top view of a package assembly compartmentalized in the surface dimensions by triangular containers according to one embodiment.

FIG. 3D is a diagram illustrating a top view of a package assembly compartmentalized in the surface dimensions by a mix of containers having various geometrical shapes according to one embodiment.

FIG. 3E is a diagram illustrating a side view of a package assembly compartmentalized in the height dimension by a mix of containers having various geometrical shapes according to one embodiment.

FIG. 4A is a flowchart illustrating a first part of a process to package a food item according to one embodiment.

FIG. 4B is a flowchart illustrating a second part of a process to package a food item according to one embodiment.

FIG. 5 is a flowchart illustrating a process to prepare a supplemental container according to one embodiment.

DETAILED DESCRIPTION

One disclosed feature of the embodiments is a technique to package a dish having strips of dough, garnishes, pieces of meat, and broth. A main container has an inner wall and is configured to be sealed with a main lid. A secondary container has an outer wall and is configured to contain a first type of broth and sealed with a secondary lid. The secondary container is placed inside the main container such that the outer wall and the inner wall form a space accommodating the strips of dough and the pieces of meat. A separator is placed above the secondary container to hold the garnishes underneath the main lid.

In the following description, numerous specific details are set forth. However, it is understood that embodiments may be practiced without these specific details. In other instances, well-known structures, and techniques have not been shown to avoid obscuring the understanding of this description.

One disclosed feature of the embodiments may be described as a process which is usually depicted as a flowchart, a flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed. A process may correspond to a method, a procedure, a method of using an apparatus or a package assembly, etc. One embodiment may be described by a schematic drawing depicting a physical structure. It is understood that the schematic drawing illustrates the basic concept and may not be scaled or depict the structure in exact proportions.

FIG. 1A is a diagram illustrating a package assembly 100, in three-dimensional view, having one inside container according to one embodiment. The package assembly 100 is designed to package a dish having liquids, solids, and fibrous components of strips of dough, garnishes, pieces of meat, and broth. The package assembly 100 is such that one component protects and preserves the property of the others. In one embodiment, the dish may be a typical Asian dish or food item, such as Vietnamese pho, bun, or mien. Typically, the dish may be served as a hot dish to be consumed like a hot soup in a bowl. The broth may be served hot or warm and may retain the heat during the time the food is being consumed. The package assembly 100 packages the dish as a take-out or to-go food item. When appropriate, the package assembly 100 may also serve for direct food consumption without the need of using a bowl or another container. The package assembly 100 includes a main container 110, a secondary container 130, and a separator 150.

The main container 110 may have any suitable shape to contain food for consumption purpose. It may have a shape of a bowl with a curved or flat bottom surface. Typically, it has a volume from about 24 oz to about 64 oz. It is configured to be sealed with a main lid 120. It may be made of polypropylene, acrylic, polycarbonate, polyactic acid, etc. In one embodiment, it may be made by plastic. In addition, it may be made of clear plastic to provide a transparent view of the contents. This may add to appealing aspects of the take-out food. Furthermore, when the main container 110 is used to contain the food elements for direct consumption as a bowl, it may be made of plastic or material that is microwavable for proper heating. In general, each of the containers of the package assembly 100 may be made of material that is suitable for its contents. In particular, when a container contains the broth, it may be made of microwavable plastic and it may have a lid. Other containers may be made of paper, foam, or plastic as appropriate.

The secondary container 130 may have any suitable shape. It typically has a size smaller than the main container 110. It is configured to contain the broth. It may have a volume from 8 oz to 32 oz. When there are more than one types of broth, it typically contains the main broth. In one embodiment, the secondary container 130 may be made of plastic. Since it contains the broth, it may also be made of plastic that is microwavable so that the broth may be heated to reach proper temperature for suitable food consumption.

The secondary container 130 may be placed inside the main container 110, typically in the center. The strips of dough 160 and the pieces of meat 170 may be placed around the secondary container 130. The strips of dough 160 may be rice noodles, rice vermicelli, or cellophane noodles. The pieces of meat 170 may be cuts of beef (e.g., steak, fatty flank, lean flank). They may also be pieces of brisket, tendon, tripe, meatballs, or chicken. In a typical scenario, the food is prepared for ready to serve or instant consumption. Accordingly, the noodles 160 may be cooked and become flexible and may be somewhat sticky. The pieces of meat 170 may be placed on top of the noodles 160. It may or may not be separated by a separator similar to the separator 150 from the noodles 160. By being placed in the space and around the secondary container 130, the cooked noodles 160 may act as a cushion to keep the secondary container 130 in place inside the main container 110. The solids, the noodles 160 and the meat 170, may also serve as insulator preventing the heat in the broth inside the secondary container 130 from being transferred to the outside air during transportation, a desirable feature when the heat is intended to be preserved.

The separator 150 may be placed above the secondary container 130 and the solids to hold the garnishes 180 underneath the main lid 120. When there is only one container inside the main container 110 such as the secondary container 130, the separator 150 may be placed on top of the secondary container 130. The separator 150 may be made of any material that is suitable for its function, such as paper, foam, or plastic. In one embodiment, the separator 150 may be made of plastic and may have a flat surface. It is typically sized to fit the periphery of the inner wall of the main container 110. By having its size fitting the inner wall of the main container 110, the separator 150 may help reinforce the mechanical stability of the package assembly 100 and prevent transfer of flavors between garnishes and the meat. Together with the cooked noodles 160 that provide a cushion for the secondary container 130, the separator 150 further strengthens the force that keeps the secondary container 130 in place inside the main container 110. This may help keep the secondary container 130 from shifting or moving around and therefore avoid possible spillage of the broth in the secondary container 130.

The garnishes 180 may be placed on the separator 150. In one embodiment, the garnishes 180 may include at least one of greens, herbs, vegetables, onions, Thai basil, bean sprouts, coriander, cilantro, lemon or lime wedges, and slides of green pepper. Other components may be placed on the separator 150 such as a spoon, a fork, or pair of chopsticks, and small supplemental containers of hoisin sauce and chili sauce.

FIG. 1B is a diagram illustrating a package assembly 100, in side view, having one inside container according to one embodiment. The package assembly 100 shown in FIG. 1B is essentially similar to that shown in FIG. 1A, having the same components. The side-view diagram, however, shows additional elements. To maintain clarity of the illustration, only relevant components are shown with the same labels as in FIG. 1A. In subsequent figures, only side views are shown for clarity. It is understood that these side views are illustrative only and they depict the same components as in corresponding three-dimensional views.

The main container 110 has an inner wall 117. The secondary container 130 has an outer wall 135. The secondary container 130 may contain the main broth, or a first type of broth 115. It may be sealed by a secondary lid 140. As described above, the inner wall 117 of the main container 110 and the outer wall 135 of the secondary container 130 may form a space surrounding the secondary container 130 that may be sufficiently large to accommodate the strips of dough 160 and the pieces of meat 170. The strips of dough, or noodles, 160 may be spread out in this space around the secondary container 130 on the bottom surface of the main container 110. When there is only one container inside the main container 110 such as the secondary container 130, the separator 150 may be placed on top of the secondary container 130, i.e., on top of the secondary lid 140.

As discussed above, the separator 150 may provide a platform for placement of the garnishes 180. The upper surface of the separator 150, the inner wall 117 of the main container 110, and the inner wall of the main lid 120 form an independent space for garnishes and any other ingredients or elements as needed.

FIG. 2A is a diagram illustrating a package assembly 200A having two inside containers stacked on each other according to one embodiment. The package assembly 200A has the same components as in the package assembly 100 but with the addition of a supplemental container 210.

The supplemental container 210 is configured to contain a second type of liquid or broth 215, or other additional food items such as sauce, desserts, etc. The second type may be the same as, or different from, the first type. It has an outer wall 235 and is configured to be sealed with a supplemental lid 220. It may have the same size and shape as the secondary container 130. The supplemental container 210 may be made of any material suitable for its contents. For example, it may be made of paper, foam, or plastic. In one embodiment, the supplemental container 210 may be made of plastic. Since it may contain the broth, like the secondary container 130, it may also be made of plastic that is microwavable so that the broth may be heated to reach proper temperature for consumption.

The supplemental container 210 may be placed on top of the secondary container 130 such that the outer wall 235 is aligned with the outer wall 135 of the secondary container 130 (when the two containers are of approximately equal sizes). It may be placed below the separator 150. The supplemental container 210 may be stacked on top of the secondary container 130 or it may be placed on top of the secondary container 130 such that the supplemental lid 220 faces the secondary lid 140.

FIG. 2B is a diagram illustrating a package assembly 200B having two inside containers separated by a separator according to one embodiment. The package assembly 200B has the same components as the package assembly 200A with the exception that the secondary container 130 and the supplemental container 210 are separated by the separator 150. To maintain clarity of the illustration, only relevant components are shown with the same labels as in FIG. 2A.

The package assembly 200B shows a variation of the package assembly 200A. In this variation, the supplemental container 210, because of the properties of its contents, may be placed above the separator 150 and in the space reserved for the garnishes 180. For example, cold or warm desserts may be suitably surrounded by the garnishes 180. The supplemental container 210 is shown as typical and represents more than one of such supplemental container and their contents may be varied. FIG. 2B shows that one or more supplemental containers may be placed above the separator 150 and among the garnishes 180.

While the cooked noodles 160 and/or the separator 150 may help provide mechanical force to keep the secondary container 130 and/or the supplemental container 210 from moving around during transportation, there may be cases where stronger mechanical force may be needed.

FIG. 3A is a diagram illustrating a package assembly 300A having two inside guides according to one embodiment. The package assembly 300A may provide stronger mechanical stability than the package assemblies 100, 200A, and 200B. The package assembly 300A may retain the same components as shown in FIGS. 1A and 1B or FIGS. 2A and 2B. To maintain clarity of the illustration, only relevant components are shown with the same labels as in FIGS. 1A and 1B and FIGS. 2A and 2B. In addition, for illustrative purposes, the package assembly 300A is shown to have the secondary container 130 and the supplemental container 210. As is known by one skilled in the art, the package assembly 300A may have only the secondary container 130. In addition to the same components as shown in FIGS. 1A, 1B, 2A and 2B, the package assembly 300 has first and second guides 310 and 320.

The first and second guides 310 and 320 may serve three purposes. First, they may provide mechanical guide to position the secondary container 130 and/or the supplemental container 210. Second, they may provide mechanical support to increase mechanical stability for the containers. Third, they may replace the separator 150 and compartmentalize the noodles and the pieces of meat.

The first and second guides 310 and 320 may be made of plastic or a suitable material. They may be placed around the secondary container 130, or the secondary container 130 and the supplemental container 210. Each of them may have a shape that fits the space between the inner wall 117 of the main container 110 and the outer wall 135 of the secondary container 130 and the outer wall 235 of the supplemental container 210. Each of them may be formed by vertical posts on a surface that fits the bottom surface of the main container 110. Alternatively, each of them may be shaped as a hollow container. The noodles and the meat may no longer be stratified in layers but placed inside or within the periphery of the first and second guides 310 and 320.

Other techniques to provide mechanical support for the secondary container 130 and the supplemental container 210 may be possible. For example, the bottom surface of the main container 110 may have a guide that fits the bottom portion of the secondary container 130. The secondary container 130 may be inserted inside this guide. Similarly, the separator 150 may have a guide on its bottom surface that fits the bottom portion of the supplemental container 210 so that when it is placed on the supplemental container 210, it may keep the supplemental container 210 firmly in place. In another embodiment, the secondary lid 140 and the supplemental lid 220 may be tooled so that they may be snapped on to secure to each other. These techniques may be used separately or together to further strengthen the mechanical stability of the containers during transportation.

As discussed above, the main container 110 typically has a shape of a bowl so that it may be used for food consumption when the secondary container 130 and the supplemental container 210 (when used) are removed. When this aspect of the embodiments is not important or not necessary, the main container 110 may have any other suitable shapes and sizes. With arbitrary shapes, the main container 110 may accommodate a wide range of arrangements of inside containers to store and contain food items in a mechanically stable manner. The concept of the using the guides as shown in FIG. 3A may be extended to allow inside containers (e.g., the secondary container 130 and/or the supplemental container 210) to be used not just to contain food components in a well-organized manner but also to act as mechanical support structures to keep them well positioned and securely in place. These inside containers may have shapes such that they may be tightly fit within the main container 110. Any arrangement of inside containers having suitable shapes and sizes that keep them tightly fit inside the main container 110 may provide this mechanical stability to avoid containers shifting around during transportation. The inside containers may be arranged to achieve compactness with respect to a flat surface or with respect to the height dimension. FIGS. 3B, 3C, 3D, and 3E show some examples of these types of arrangement. The compartmentalization of the main container 110 may be performed with respect to the surface (e.g., horizontal) dimensions or with respect to the height (e.g., vertical) dimension, or a combination of the surface dimensions and the height dimension.

FIG. 3B is a diagram illustrating a top view of a package assembly 300B compartmentalized in the surface dimensions by square or rectangular containers according to one embodiment. In the package assembly 300B, the main container 110 may have an overall square or rectangular shape. There are four inside containers A, B, C and D. Each of them may have a square or rectangular shape. They fit tightly inside the main container 110.

FIG. 3C is a diagram illustrating a top view of a package assembly 300C compartmentalized in the surface dimensions by triangular containers according to one embodiment. In the package assembly 300C, the main container 110 may have an overall triangular shape. There are four inside containers A, B, C and D. Each of them may have a triangular shape. They fit tightly inside the main container 110.

FIG. 3D is a diagram illustrating a top view of a package assembly 300D compartmentalized in the surface dimensions by a mix of containers having various geometrical shapes according to one embodiment. In the package assembly 300D, the main container 110 may have an overall polygonal shape (e.g., hexagon). There are four inside containers A, B, C and D. The containers A and B may have rectangular shapes. The containers C and D may have cylindrical shapes and are positioned at the two corners of the polygonal structure. This example shows that a mix of inside containers having different sizes and shapes may be used as long as their placements inside the main container 110 provide a mechanically stable arrangement.

FIG. 3E is a diagram illustrating a side view of a package assembly 300E compartmentalized in the height dimension by a mix of containers having various geometrical shapes according to one embodiment. The package assembly 300E may have three compartments in a vertical arrangement. The bottom compartment has two containers A and B. The container A 352 may contain liquid such as broth. Since it contains liquid, it has a lid 354 to prevent the liquid from spilling out. The containers A (with the lid 354) and B have approximately equal heights so that a separator 356 may be placed on top of them as a flat surface. The separator 356 provides a platform for containers C and E. A separator 358 is placed on the container C to define a compartment D. The two separators 356 and 358, together with the inner wall of the lid 120, may therefore form three compartments in the vertical direction.

FIG. 4A is a flowchart illustrating a first part of a process 400 to package a food item according to one embodiment.

Upon START, the process 400 puts a first type of broth in a secondary container having an outer wall (Block 410). Next, the process 400 seals the secondary container with a secondary lid (Block 415). Then, the process 400 determines if guides are needed (Block 420). If so, the process 400 places the guides inside the main container (Block 425) and proceeds to block 430. If guides are not needed, the process 400 places the sealed secondary container inside the main container having an inner wall such that the outer wall of the secondary container and the inner wall of the main container form a space (Block 440). The sealed secondary container may be flanked by the guides if the guides are used.

Next, the process 400 puts the strips of dough, e.g., the cooked noodles and the pieces of meat in the space surrounding the sealed secondary container (Block 435). Typically, the cooked noodles are placed first on the bottom surface of the main container and the pieces of meat are placed on the cooked noodles. Meat may touch noodles without damaging the quality of either of them and therefore, in some cases, a separator may not be needed. The process 400 then continues to a process connector A.

FIG. 4B is a flowchart illustrating a second part of a process 400 to package a food item according to one embodiment.

From the connector A, the process 400 determines if the supplemental container is needed (Block 440). If not, the process 400 places a separator on the secondary container (Block 445) and then proceeds to Block 470. Otherwise, the process 400 prepares the supplemental container (Block 450) as illustrated in FIG. 5. Then, the process 400 determines if the second and supplemental containers are to be separated (Block 455). If so, the process 400 places a separator on top of the secondary container (Block 475). Then, the process 400 places the supplemental container on the separator (Block 480). Next, the process 400 puts garnishes and other ingredients on the separator and around the supplemental container (Block 485) and then proceeds to Block 490.

If the secondary containers and the supplemental containers are not to be separated, the process 400 places the supplemental container on top of the secondary container (Block 460) as illustrated in FIG. 3A. In one embodiment, the process 400 places the supplemental container on top of the secondary container such that the supplemental lid faces the secondary lid. Then, the process 400 places the separator on top of the supplemental container (Block 465).

Next, the process 400 puts the garnishes on the separator (Block 470). Additional items such as spoon, chopsticks may also be put on the separator. Then, the process 400 seals the main container with a main lid (Block 490) and is then terminated.

FIG. 5 is a flowchart illustrating the process 450 to prepare a supplemental container according to one embodiment.

Upon START, the process 450 puts a second type of broth in a supplemental container (Block 510). The second type may be the same as, or different from, the first type. Alternatively, the process 450 puts any other ingredients or additional food items (e.g., sauce, desserts) in the supplemental container. Next, the process 450 seals the supplemental container with a supplemental lid (Block 520). The process 450 is then terminated.

It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. 

What is claimed is:
 1. A package assembly to package a dish having strips of dough, garnishes, pieces of meat, and broth, the package assembly comprising: a main container having an inner wall and configured to be sealed with a main lid; a secondary container having an outer wall and configured to contain a first type of broth and sealed with a secondary lid, the secondary container placed inside the main container such that the outer wall and the inner wall form a space accommodating the strips of dough and the pieces of meat; and a separator placed above the secondary container to hold the garnishes underneath the main lid.
 2. The package assembly claim 1 further comprising: a supplemental container configured to contain a second type of broth and to be sealed with a supplemental lid, the supplemental container placed on top of the secondary container and below the separator.
 3. The package assembly claim 2 wherein the supplemental container is placed on top of the secondary container such that the supplemental lid faces the secondary lid.
 4. The package assembly of claim 1 wherein at least one of the main and secondary containers and the separator is made of plastic.
 5. The package assembly of claim 2 wherein at least one of the main, secondary, and supplemental containers, and the separator is made of plastic.
 6. The package assembly of claim 1 wherein the secondary container is made of plastic that is microwavable.
 7. The package assembly of claim 2 wherein the supplemental container is made of plastic that is microwavable.
 8. The package assembly of claim 1 wherein the strips of dough include one of rice noodles, rice vermicelli, and cellophane noodles.
 9. The package assembly of claim 1 wherein the garnishes include at least one of greens, herbs, vegetables, onions, basil, bean sprouts, coriander, cilantro, lemon wedges, and lime wedges.
 10. The package assembly of claim 1 wherein the pieces of meat include at least one of cuts of beef, flank, brisket, tendon, tripe, meatballs, and chicken.
 11. A method of packaging a dish having strips of dough, garnishes, pieces of meat, and broth, the method comprising: putting a first type of broth in a secondary container having an outer wall; sealing the secondary container with a secondary lid; placing the sealed secondary container inside a main container having an inner wall such that the outer wall and the inner wall form a space; putting the strips of dough and the pieces of meat in the space surrounding the sealed secondary container; placing a separator above the secondary container; putting the garnishes on the separator; and sealing the main container with a main lid.
 12. The method of claim 11 further comprising: putting a second type of broth in a supplemental container; sealing the supplemental container with a supplemental lid; and placing the supplemental container on top of the secondary container and below the separator.
 13. The method of claim 12 wherein placing the supplemental container comprises placing the supplemental container on top of the secondary container such that the supplemental lid faces the secondary lid.
 14. The method of claim 11 wherein at least one of the main and secondary containers and the separator is made of plastic.
 15. The method of claim 12 wherein at least one of the main, secondary, and supplemental containers, and the separator is made of plastic.
 16. The method of claim 11 wherein the secondary container is made of plastic that is microwavable.
 17. The method of claim 12 wherein the supplemental container is made of plastic that is microwavable.
 18. The method of claim 11 wherein the strips of dough include one of rice noodles, rice vermicelli, and cellophane noodles.
 19. The method of claim 11 wherein the garnishes include at least one of greens, herbs, vegetables, onions, basil, bean sprouts, coriander, cilantro, lemon wedges, and lime wedges.
 20. The method of claim 11 wherein the pieces of meat include at least one of cuts of beef, flank, brisket, tendon, tripe, meatballs, and chicken.
 21. The method of claim 11 further comprising: putting a second type of broth in a supplemental container; sealing the supplemental container with a supplemental lid; and placing the supplemental container on the separator. 